Vehicle-Mounted 3D Printing Rate Control Under Vibration
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Solution Overview
Problem
Existing methods for delivering replacement parts to vehicles and machines are inefficient, leading to prolonged downtime due to extensive lead times for high-quality parts, and 3-D printing technologies face challenges when operating on moving vehicles subjected to external forces like vibrations and changes in direction.
Innovation Solution
A method for controlling a 3-D printer on a vehicle by adjusting the printing rate based on current and expected forces affecting the printer, using sensors to detect and compare these forces with predefined thresholds, allowing for reliable and efficient printing of temporary replacement parts on route to the end user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the printing rate is increased to reduce lead time for replacement parts, then productivity is improved, but manufacturing precision deteriorates due to vibrations and external forces affecting the moving vehicle
Solution Approach 1:
The printing rate is made dynamic rather than fixed. The system continuously monitors vibration levels and external forces acting on the vehicle, and automatically adjusts the printing rate in real-time. When vibrations are low, the printing rate increases to maintain productivity; when vibrations exceed thresholds, the printing rate decreases to ensure manufacturing precision. This dynamic adaptation resolves the contradiction between speed and quality.
Solution Approach 2:
The system changes the operating parameters of the 3-D printer based on detected environmental conditions. By monitoring vibration amplitude, frequency, and external forces, the system adjusts critical printing parameters such as printing rate, nozzle temperature, and layer thickness. This parameter adaptation allows the system to maintain part quality across varying vehicle motion conditions while maximizing overall productivity.
2Loss of time
If the vehicle travels faster to deliver parts quicker, then loss of time is reduced, but reliability deteriorates due to increased vibrations and forces affecting printing accuracy
Solution Approach 1:
The system performs preliminary monitoring of vibration levels and external forces before initiating or continuing printing operations. By assessing the current vehicle motion state in advance, the system can determine whether conditions are suitable for high-speed printing. This preliminary assessment allows the system to plan printing schedules that optimize delivery time while maintaining reliability by avoiding printing during excessively violent motion periods.
Solution Approach 2:
The system implements continuous feedback monitoring of vibration sensors and force measurements during printing operations. This real-time feedback allows the system to detect deteriorating conditions and adjust the printing rate or pause operations to maintain reliability. The feedback loop ensures that printing quality is preserved even when the vehicle is in motion, resolving the contradiction between fast delivery and stable printing.
3Loss of time
If a mobile 3-D printer is installed on the vehicle to print parts on route, then loss of time is reduced, but device complexity increases due to integrating printing systems into moving vehicles
Solution Approach 1:
The mobile 3-D printer system is designed with multi-functionality to justify the added complexity. The system can print multiple different replacement parts for various vehicle components, serving as a universal solution for different breakdown scenarios. This universality makes the complex integrated system worthwhile by enabling the vehicle to carry its own manufacturing capability for numerous potential repair needs, significantly reducing service time across different part types.
Solution Approach 2:
The 3-D printer system is nested within the vehicle structure, utilizing available space efficiently. The printer, material storage, and control systems are integrated into the vehicle's existing framework, minimizing additional complexity. This nesting approach allows the mobile printing capability to be added without proportionally increasing overall system complexity, as components share space and infrastructure with the vehicle's existing systems.
Data Source
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AI summary
A method (100) for controlling an operation of a three-dimensional (3- D) printer comprised with a vehicle, wherein the method comprises the steps of receiving (110) an indication of any one of a current force and an expected force affecting the operation of the 3-D printer; comparing (120) any one of the current force and the expected force affecting the operation of the 3-D printer with a given force threshold; and adjusting (130) a printing rate of the 3-D printer based on any one of the current force and the expected force affecting the operation of the 3-D printer.